Principle/Testing of IEC
60598-1/IEC 60598-2-1
Vicky Zhang
Product Expert
DEKRA
Shanghai
IECEE Workshop
August 26 & 27
Nairobi - Kenya
IEC SYSTEM OF CONFORMITY ASSESSMENT
SCHEMES FOR ELECTROTECHNICAL
EQUIPMENT AND COMPONENTS
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Content
• Why?
• What?
• How?
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• Why to use IEC standards?
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Recalls by product categories
- 2012, EU
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Recalls by type of risk
- 2012, EU
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Product Risks
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What is product safety?
No hazards
to environment
No hazards
to People
Product
Safety
No hazards to
other equipments
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Provisions against Hazards
Electrical
Hazards
B
Mechanical
hazards A
Heat related
C
hazards
Provisions
Radiation
hazards
E
D
Fire
hazards
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Advantage of IEC standards
Representing market needs
Transparent process
IEC
Standards
Wide adoption
Bases of national standard or regulations
Reducing risk, increasing quality, confidence
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Technical committees
SC 34A
Lamps
SC 34B
Lampcaps/
holders
TC 34
Lamps and
related
equipments
SC 34D
Luminaires
SC 34C
Auxiliaries
for lamps
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• What criterias are required in
IEC 60598-1/60598-2-1?
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Standards
• IEC 60598-1
Luminaires –
Part 1: General requirements and tests
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Standards
• IEC 60598-2-1
Luminaires –
Part 2- Particular requirements for Fixed
general purpose luminaires
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Scope
• Fixed general purpose luminaire
• Working voltage <= 1000 V
• Tungsten filament, tubular fluorescent
and other discharge lamps
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Definition – Fixed luminaire
• Not easily be moved from one place to
another
• A: only be removed with the aid of a tool
or
• B: for use out of arms reach
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Classification
• Protection against electrical shock
• Class I luminaire:
basic insulation + protective earthing
• Class II luminaire:
basic + supplementary insulation or
reinforced insulation
• Class III luminaire:
SELV (safety extra-low voltage)
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Conformity Assessment
Type
Test
Routine
Test
Carried out by laboratory
To use standardized test method
To check compliance of the design of a product
Carried out by manufacturers after production
To ensure every luminaire conforms with the
sample approved under type test
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Conformity Assessment
Type
Test
Routine
Test
Carried out by laboratory
To use standardized test method
To check compliance of the design of a product
Carried out by manufacturers after production
To ensure every luminaire conforms with the
sample approved under type test
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Component
• Suitable for use in the Luminaire
• Correct Classification and Ratings
• In compliance with relevant IEC
requirements
To ensure
safety of usage
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Provision of Marking
• Marking on products
• Mounting Instructions
The height of letters and numerals ≥ 2 mm .
The height of symbol ≥ 5 mm
• Durability and legiability
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Construction - Lampholder
• Positioning test
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Construction - Lampholder
• Bending test
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Construction - Lampholder
• Torque test
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Construction – Terminal block
• Space
- Luminaire with connecting
leads requires a terminal
block to connect to fixed
wiring
- Adequate space for
terminal block
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Construction – Reliable terminals
• 8 mm conductor
• live conductor
• earth conductor
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Construction – Reliable terminals
• External cable & Internal wiring
• Retained by cord anchorage
• Clamped by spring terminal
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Construction – Reliable terminals
• Internal wiring
- Anchored to a tag
before soldering
- Twisted in a reliable
manner
- Fasten by sleeve,
tape
- Inserted into a hole
of PCB, bend and
soldered
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Construction – Reliable terminals
• Internal wiring
- Securely crimped
- Securely wrapped
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Construction – Double/Reinforced
Insulation
• Metal encased class II luminaire
- No contact between mounting surface
and part with basic insulation only
Double
insulated wire
Terminal block
with a cover
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Construction – Double/Reinforced
Insulation
• Metal encased class II luminaire
- No contact between accessible part and
basic insulation
→ Double insulated wire
→ Insulating lining, sleeve
Mechanical
strength
1.Retained by positive
means
2.Not be removed
without being seriously
damaged
Electrical
strength
Thermal
strength
1. Humidity 48 hrs
1. Thermal test
2. Insulation
resistance &
electric strength
2. T(wire)+20°C
3. Aging T(wire)+20°C, 240
hrs, checked by electrical
strength
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Construction – Screws
• Torque test
No damage
No creep
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Construction – Screws
• Torque test
• 0,5 Nm for screws on cord anchorage
bearing directly on cable or cord
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Construction – Glands
• Torque test
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Construction – Mechanical Strength
• Impact test
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Construction – Mechanical Strength
• Impact test
- Live part shall not be accessible
- Insulation shall not be impaired
- No reduction on IP protection and
classification
- Removable/replaceable part can be
removed/replaced without breakage
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Construction – Mechanical Strength
• Metal part enclosing live part
-
Pressure test by test finger
30 N
Metal part shall not touch live part
No reduction on creepage distance and
clearance
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Construction – Mechanical Strength
• All Suspended luminaires
-
Loading test
4 x weight of luminaire
1 hrs
No deformation on suspension system
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Construction – Mechanical Strength
• Rigid Suspended luminaires
-
Torque test
2,5 Nm, 1 min
Clockwise and anti-clockwise
No rotation more than one revolution in both
directions
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Construction – Mechanical Strength
• Rigid Suspension bracket (heavy duty)
- Loading 40 N, >=2,5 Nm, at free end
- 1 min
- No permanent displacement, deformation
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Construction – Mechanical Strength
• Rigid Suspension bracket (light duty)
- Loading 10 N, >=1,0 Nm, at free end
- 1 min
- No permanent displacement, deformation
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Construction – Mechanical Strength
• Track mounted luminaire
- Luminaire mass < max. load for track
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Construction – Mechanical Strength
• Adjusting device
- No twisting over 360
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Construction – Mechanical Strength
• Flexing test
- Strands broken < 50%
- Insulation resistance & electric strength
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Construction – Flammable Material
• Glow-wire test 650 C
• Spacing  30 mm
• No fiercely burning material
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External Wiring
• Supply connection
Supply cable & Plug
Adaptor for track
Terminals
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External Wiring
• Supply connection
Connecting leads
Appliance inlet
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External Wiring
• Type of cable
• 0,75 mm2 for ordinary luminaires;
• 1,0 mm2 for other luminaires
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External Wiring
• Type of connection
- Type X attachment
- Type Y attachment
- Type Z attachment
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External Wiring
• Cord anchorage
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External Wiring
• Cord anchorage
- Pull test (25 time, displacement <= 2mm)
- Torque test
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Internal Wiring
• Internal wiring directly connected to
fixed wiring
Operating current >= 2 A
Operating current < 2 A
min. 0,5 mm2
min. 0,4 mm2
Insulation thickness: min.
0,6 mm
(PVC or Rubber)
1,5 mm2 for through
wiring
Insulation thickness:
min. 0,5 mm
(PVC or Rubber)
--
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Internal Wiring
• Internal wiring connected to fixed wiring
via current limiting device <= 2 A
If current-carrying capacity and the mechanical
properties are adequate
- Cross-sectional area min. may be less than 0,4 mm2
- Insulation thickness may be less than 0,5 mm
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External & Internal Wiring
• Soldering
Clamping terminal
Spring terminal
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External & Internal Wiring
• Soldering
Spring terminal
Cold flow
Bad electrical
connection
Clamping terminal
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Earthing
• Accessible metal part, basic insulated
• Non-accessible metal part, basic
insulated, but in contact with
supporting surface
- Reliably connected to earthing
terminal or earthing contact
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Earthing
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Earthing
• Location of earthing terminal
• Adjacent to mains terminal (type X, Y)
• Material of earthing terminal
• Brass or non-rusting material
• Bare contact surface
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Earthing
• Cord for earthing
• Green-yellow cord shall only be used
for earthing connection
• Earthing make contact first
• Earthing detached later
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Earthing
• Terminal blocks with integrated
screwless earthing contacts
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Earthing
• Terminal blocks with integrated
screwless earthing contacts
• Pull test 20 N – terminal block shall be in
place
• Pull test 50 N – applies only to earthing
contact – no damage, no loosen on
earthing contact
• Earthing contact – supporting plate
< 0,05 ohm
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Earthing
• Terminal blocks with integrated
screwless earthing contacts
• Voltage drop test
• Resistance < 0,05 ohm
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Protection against electrical shock
• Live parts not accessible when
luminaire installed and wired as in
normal use or during lamp/starter
replacement
- Wall-mounted luminaires: within arm reach,
no access to basic insulated parts by means of
a Ø 50 mm probe
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Protection against electrical shock
• Basis insulated parts of Class II
luminaires to be regarded as live parts
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Protection against electrical shock
• No basic insulated components on
outside of luminaire
• Luminaires incorporating a capacitor
>0,5μF must be provided with a
discharge device
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Resistance to dust and moisture
• Dust Test (IP#X)
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Resistance to dust and moisture
• Dust Test (IP#X)
• Solid-objectproof (IP2X)
• Solid-objectproof (IP3X or
IP4X)
• Dust-proof
(IP5X)
• Dust-tight proof
(IP6X)
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Resistance to dust and moisture
• IP Test (IPX#)
• Drip-proof (IPX1)
• Drip-proof (IPX2)
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Resistance to dust and moisture
• IP Test (IPX#)
• Rain-proof (IPX3) and splash-proof (IPX4)
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Resistance to dust and moisture
• IP Test (IPX#)
• Jet-proof (IPX5) and powerful water jet-proof
(IPX6)
IP X5
15 min / distance = 3 m / 12,5 l/min ± 5 % (30 kN/m2)
IP X6
3 min / distance = 3 m / 100 l/min ± 5 % (100 kN/m2)
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Resistance to dust and moisture
• IP Test (IPX#)
• Watertight (IPX7)
•
30 min in water / 150 mm of water above the top of
the speciment and the lowest portion is subjected
to at least 1 m head of water
• Pressure watertight (IPX8)
•
30 min in water / water pressure 1,3 x pressure
which corresponds to the rated maximum
immersion depth
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Resistance to dust and moisture
• Humidity test
• R.H. 91% to 95 %
• 10 ºC – 30 ºC
• 48 hrs
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Insulation Resistance
• Class I luminaire: 2 Mohm
• Class II luminaire:
• Basic/Supplementary insulation: 2
Mohm
• Double/Reinforced insulation: 4 Mohm
• Class III luminaire: 1 Mohm
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Electric Strength
• Class I luminaire: 2U + 1000 V
• Class II luminaire:
• Basic/Supplementary insulation: 2U
+ 1000 V
• Double/Reinforced insulation: 4U + 2000 V
• Class III luminaire: 500 V
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Creepage distance & Clearances
•
•
•
•
Live Parts of different polarity
Live Parts  Adjacent Metal Parts
Live Parts  Body or Housing
Live Parts  Mounting Surface
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Creepage distance & Clearances
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Endurance and Thermal test
•
•
•
•
Endurance
 7 or 10 Days
Thermal Test  Normal operation
Thermal Test  Abnormal operation
Thermal Test on luminaires classified
for mounting on normally flammable
surfaces
• Thermal Test on thermalplastic
luminaires
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Resistance to heat, fire and tracking
• Ball Pressure Test
• Needle Flame Test
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Resistance to heat, fire and tracking
• Glow-wire Test 650 ºC
• Tracking Test on IP>20
Luminaire
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Conformity Assessment
Type
Test
Routine
Test
Carried out by laboratory
Use standardized test method
To check compliance of the design of a product
Carried out by manufacturers after production
To ensure every luminaire conforms with the
sample approved under type test
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Routine test by Manufacturer
• Visual check
• Function test
• Earth continuity (earthing resistance:
0,05ohm)
• Electric strength or insulation
resistance (for metal encased)
• Polarity (for Class I luminaire)
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• How to build up a laboratory
carrying out testing of IEC
60598-2-1?
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What is a laboratory?
• Area where tests are conducted
(electrical, chemical, physical, mechanical etc.)
Why are tests conducted in a
laboratory?
• External influences on the test results
are ruled out!
• Conditions for testing are controlled!
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Conditions which can influence
test results in your laboratory?
Manpower
Machines
Human factors
Environmental conditions
Equipment
Methods
Test methods/validation
Measurement traceability
Sampling
Handling of test items
Means
Consumable goods/ items
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Process model
Manpower
Input
Machines
Output
Process
Means
Methods
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Manpower
Machines
Manpower
Input
•
•
•
•
Output
Process
Competent staff
Staff in training (adequate supervision needed)
Personnel competent and qualified
Goals and policy / procedures for training and
qualification requirements
• Job descriptions (management, technical and
supporting)
• Records of all personnel maintained, readily
available (authorizations, competences,
qualifications, training, skills, experience…)
Means
Methods
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Manpower
Machines (1)
Input
Machines
Output
Process
Means
Methods
• Facilitate correct performance of tests
• Technical requirements that can effect the
results documented
• Monitor, control, record environmental
conditions and stop testing when
environmental conditions jeopardize results
• Effective separation of incompatible areas
• Access and use shall be defined and
controlled
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Manpower
Machines (2)
Input
Machines
Output
Process
Means
Methods
• Lab with all equipments required for the correct
performance of tests
• Equipment capable of achieving accuracy
needed
• Authorized personnel; up to date instructions
• Unique identification
• List of records for each piece of equipment
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Manpower
Machines (3)
Input
Machines
Output
Process
Means
Methods
• IECEE – CTL testing equipments under CB
scheme
http://www.iecee.org/ctl/equipment/html/ctl_testing_lite.htm
• IECEE-CTL Operational Procedures
CTL-OP 108
Use of thermocouples
CTL-OP 109
Acceptance of thermocouples
CTL-OP 110
Procedure for measuring power source characteristic
CTL-OP 111
Traceability of calibrations and calibration intervals
• http://www.iecee.org/ctl/operational/Operational_procedures.htm
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Manpower
Machines (4)
Input
Machines
Output
Process
Means
Methods
• Refer to CTL-OP 110 “Procedure for
Measuring Laboratory Power Source
Characteristics”
8.1 When not otherwise specified in the testing standard, the
power source used for testing shall meet the following
requirements:
A. Voltage stability: ± 3 % maximum
B. Frequency stability: ± 2 % maximum
C. Total harmonic distortion (THD): maximum 5 %
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Manpower
Machines (5)
Input
Machines
Output
Process
Means
Methods
• Note:
IEC 60598-1, cl. 12.4.1 e) ±1% (preferred ± 0.5%)
voltage stability instead of ± 3%!
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Manpower
Machines (6)
Input
Machines
Output
Process
Means
Methods
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Manpower
Machines (7)
Input
Machines
Output
Process
Means
Methods
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Manpower
Machines (8)
Input
Machines
Output
Process
Means
Methods
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Manpower
Machines (9)
Input
Machines
Output
Process
Means
Methods
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Manpower
Methods
Input
Output
Process
Means
•
•
•
•
Machines
Methods
Appropriate methods for all tests within scope
Instructions for all equipment
Up to date and readily available to personnel
Methods must meet the requirements of
standards
• Latest valid editions of standards to be used
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Manpower
Means
Input
Machines
Output
Process
Means
Methods
• Policy and procedures for selection & purchase
of services and supplies, when relevant for
tests
• Procedures for inspecting supplies prior to use
• Purchasing documents reviewed and approved
for technical content prior to release
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Manpower
Input
Input
Machines
Output
Process
Means
Methods
• Review of requests, tenders and contracts
•
•
•
•
•
Methods adequately defined
Posses capability and resources
Differences resolved before work begins
Record of reviews maintained, including
discussion with clients
Any subcontracted work
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Manpower
Output
Input
Machines
Output
Process
Means
Methods
• Reporting results
• Shall include all information requested by the client
and all information required by the method used
• Subcontracted results clearly identified
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Manpower
Output
Input
Machines
Output
Process
Means
Methods
• IECEE – TRF (test report form)
http://members.iecee.org/
• IECEE – TRF guide
•
OD-2020
•
http://www.iecee.org/Operational_documents/odcb_index.html
Vicky Zhang
Product Expert
DEKRA Shanghai
IECEE Workshop
August 26 & 27
Nairobi - Kenya
IEC SYSTEM OF CONFORMITY ASSESSMENT
SCHEMES FOR ELECTROTECHNICAL
EQUIPMENT AND COMPONENTS